Aluminum oxide reinforced aluminum-based composite material for wind power blade component and preparation method of aluminum oxide reinforced aluminum-based composite material

Abstract

The preparation method comprises the following steps: firstly, ultrasonically dispersing nano rod-shaped zirconium boride, aluminum metal powder, nano diamond and active silicon powder in an ethanol water solution, then adding an auxiliary agent, performing ultrasonic oscillation uniformly, centrifuging to take precipitate, drying to obtain mixed powder, and performing cold pressing to obtain the aluminum oxide reinforced aluminum matrix composite for the wind power blade part. Obtaining a prefabricated body; placing an aluminum ingot in a graphite mold at the bottom of a furnace chamber of a vacuum infiltration furnace, placing the preform in the upper part of the furnace chamber of the vacuum infiltration furnace, sealing the vacuum infiltration furnace, heating the aluminum ingot to be molten to obtain molten metal, preheating the preform, immersing the preheated preform into the molten metal, stopping heating, introducing mixed gas of oxygen and nitrogen into the vacuum infiltration furnace, and carrying out vacuum infiltration; generating aluminum oxide, aluminum nitride and silicon carbide in situ, and stopping introducing the mixed gas after the temperature in the vacuum infiltration furnace is naturally cooled to room temperature, so as to obtain a green body; and finally, carrying out microwave sintering treatment on the green body under the conditions of vacuum and alternating magnetic field, so as to obtain the ceramic.

Description

Technical Field

[0001] The present invention belongs to the technical field of wind power generation equipment manufacturing, and in particular relates to an alumina reinforced aluminum-based composite material for wind power blade components and a preparation method thereof. Background Art

[0002] Conventional energy sources like coal-fired and oil-fired power, as well as nuclear power, can cause environmental pollution. In contrast, wind energy is inexhaustible and a pollution-free, renewable energy source. In recent years, wind power technology has developed rapidly, resulting in reliable product quality, high availability, and power generation costs approaching those of coal-fired power, demonstrating excellent economic efficiency and positive growth momentum.

[0003] As the core of wind turbines, the quality and performance of wind turbine blade components are key to ensuring the normal and stable operation of wind turbines. Since wind turbine blade components are exposed to harsh environments such as ultraviolet rays, wind and sand, rain erosion, salt spray, humidity, heat, and temperature differences for a long time, and need to operate continuously for a long time, wind turbine blade components should meet the following requirements:

[0004] 1. It has a light weight and the best fatigue strength and mechanical properties, and can withstand extreme conditions such as storms and random loads;

[0005] 2. The elasticity, inertia during rotation and vibration frequency characteristic curve of the blades are all normal, and the load stability transmitted to the entire power generation system is good;

[0006] 3. Smooth surface to reduce wind resistance;

[0007] 4. Good resistance to corrosion, ultraviolet radiation and lightning strike;

[0008] 5. It must not generate strong electromagnetic interference and light reflection;

[0009] 6. Excessive noise is not allowed;

[0010] 7. Low power generation cost and low maintenance cost.

[0011] Currently, wind power generation is developing toward high power and long blades, placing stricter quality requirements on wind turbine blade components. The manufacturing materials for wind turbine blade components have evolved from wooden blades and cloth-covered blades to glass fiber-reinforced polyester resin blades, glass fiber-reinforced epoxy resin blades, and carbon fiber-reinforced epoxy resin blades. However, blades made from these materials are heavy and have poor electrical conductivity, resulting in poor lightning protection. They also face challenges such as high cost, high pollution levels during the raw material manufacturing process, and non-renewable raw material sources (the raw materials are derived from petroleum). In comparison, aluminum-based materials are lightweight and easy to process, making them an ideal material for wind turbine blade components. However, issues such as oxidation and aging in air limit their application in wind turbine blade component manufacturing.

[0012] Patent application CN101929434A discloses a wind turbine blade made of a cast aluminum alloy, preferably an aluminum-magnesium alloy. This patent application directly uses aluminum alloys such as aluminum-magnesium alloys in the manufacture of wind turbine blades, but fails to overcome the technical drawbacks inherent in aluminum alloys. Summary of the Invention

[0013] In view of the shortcomings of the prior art, the object of the present invention is to provide an alumina reinforced aluminum-based composite material for wind turbine blade components and a preparation method thereof.

[0014] In order to achieve the above object, the present invention adopts the following technical solutions:

[0015] The present invention provides a method for preparing an alumina-reinforced aluminum-based composite material for wind turbine blade components, the specific steps of which are as follows:

[0016] (1) First, nanorod-shaped zirconium boride, aluminum metal powder, nanodiamond, and active silicon powder are ultrasonically dispersed in an ethanol aqueous solution, and then an auxiliary agent is added, ultrasonically vibrated evenly, centrifuged to obtain a precipitate, dried to obtain a mixed powder, and cold pressed to obtain a preform;

[0017] (2) then placing the aluminum ingot in a graphite mold at the bottom of the vacuum impregnation furnace, placing the preform in the upper part of the vacuum impregnation furnace, sealing the vacuum impregnation furnace, heating the aluminum ingot until it melts to obtain molten metal, and immersing the preform in the molten metal after preheating. Heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide, aluminum nitride, and silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0018] (3) Finally, the green body is subjected to microwave sintering treatment under vacuum and alternating magnetic field conditions to obtain the alumina reinforced aluminum-based composite material.

[0019] Preferably, the mass ratio of nanorod-shaped zirconium boride, aluminum metal powder, nanodiamond, active silicon powder, ethanol aqueous solution, additive, and aluminum ingot is 0.05-0.07:1-1.2:0.12:0.28:6-8:1-2:10, the volume concentration of ethanol aqueous solution is 40-50%, and the additive is obtained by mixing polyvinyl alcohol 200, polyethyleneimine, etc.

[0020] Preferably, in step (1), the nanorod-shaped zirconium boride is prepared by the following method, in parts by weight: first, 30 to 35 parts of zirconium oxide, 10 to 12 parts of boron carbide, 5 to 6 parts of amorphous carbon, 15 to 20 parts of sodium chloride, and 25 to 30 parts of potassium chloride are uniformly mixed, and then irradiated with 800 to 1000 W microwaves for 8 to 10 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 3 to 5 times, and vacuum dried to obtain the obtained product.

[0021] Preferably, in step (1), the ultrasonic dispersion conditions are: 400-500W ultrasonic dispersion for 20-30 minutes; the ultrasonic oscillation uniformity conditions are: 600-700W ultrasonic oscillation treatment for 40-50 minutes.

[0022] Preferably, in step (1), the cold pressing conditions are: 50-60 MPa cold pressing for 20-30 minutes.

[0023] Preferably, in step (2), the aluminum ingot is heated to 780-800° C. and kept warm for 1-2 hours to obtain molten metal.

[0024] Preferably, in step (2), the preform is preheated by heating to 580-600° C. at a temperature of 8-10° C. / min and keeping the temperature for 1-2 hours.

[0025] Preferably, in step (2), the flow rate of the mixed gas is 1 to 2 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas is 7:3.

[0026] Preferably, in step (3), the alternating magnetic field conditions are: magnetic induction intensity is 3 to 4 T, and frequency is 60 to 80 Hz.

[0027] Preferably, in step (3), the microwave sintering frequency is 800-1000 MHz, and the specific process is as follows:

[0028] (A) sintering at 300-500W for 20-30 minutes;

[0029] (B) sintering at 700-800W for 3-5 minutes;

[0030] (C) Sinter at 400-600W for 5-7 minutes.

[0031] The present invention also provides an alumina reinforced aluminum-based composite material for wind turbine blade components, which is prepared by the above method.

[0032] The present invention also provides the use of the aforementioned alumina reinforced aluminum-based composite material in the manufacture of wind turbine blade components.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] The present invention provides an alumina-reinforced aluminum-based composite material for wind turbine blade components and a preparation method thereof. Nanorod-shaped zirconium boride, aluminum metal powder, nanodiamonds, and activated silicon powder are first ultrasonically dispersed in an ethanol-water solution. Auxiliary agents are then added and ultrasonically vibrated uniformly. The precipitate is centrifuged and dried to obtain a mixed powder, which is then cold-pressed to obtain a preform. An aluminum ingot is then placed in a graphite mold at the bottom of a vacuum impregnation furnace. The preform is then placed in the upper portion of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until molten to obtain molten metal. The preform is then preheated and immersed in the molten metal. Heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to in-situ generate alumina, aluminum nitride, and silicon carbide. After the temperature in the vacuum impregnation furnace cools naturally to room temperature, the mixed gas introduction is stopped to obtain a green body. Finally, the green body is microwave-sintered under vacuum and alternating magnetic field conditions. The alumina-reinforced aluminum-based composite material obtained by the present invention has excellent mechanical properties, good aging resistance, and corrosion resistance, and is suitable for the manufacture of wind turbine blade components.

[0035] The present invention preheats the preform and then immerses it in the metal liquid obtained by heating and melting the aluminum ingot. The preform contains nano-rod-shaped zirconium boride, aluminum, nano-diamonds, active silicon powder, etc. As a mixed gas of oxygen and nitrogen is introduced, aluminum oxide, aluminum nitride, silicon carbide, etc. can be generated in situ.

[0036] The synergistic effect of nanorod-shaped zirconium boride, aluminum oxide, aluminum nitride, and silicon carbide contributes to improved performance of the aluminum-based composite. Furthermore, microwave sintering of the green body under vacuum and alternating magnetic field conditions optimizes the microstructure of the aluminum-based composite through the coupling of the alternating magnetic field and microwaves, promoting the crystallization of silicon carbide and further improving its performance.

[0037] The microwave sintering treatment adopts three steps and three different microwave power ranges in sequence. Compared with the one-step treatment with fixed microwave power, it is more conducive to the optimization of the product microstructure and the improvement of the performance of aluminum-based composite materials. DETAILED DESCRIPTION

[0038] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0039] Unless otherwise specified, all commodities in this invention are purchased through market channels.

[0040] Example 1

[0041] A method for preparing an alumina-reinforced aluminum-based composite material for wind turbine blade components, comprising the following specific steps:

[0042] (1) First, 0.05 kg of nanorod-shaped zirconium boride, 1 kg of aluminum metal powder, 0.12 kg of nanodiamond, and 0.28 kg of active silicon powder were ultrasonically dispersed in 6 kg of 40% ethanol aqueous solution, and then 1 kg of auxiliary agent (polyvinyl alcohol 200, polyethyleneimine, etc.) was added. Ultrasonic vibration was uniformly applied, and the precipitate was centrifuged and dried to obtain a mixed powder, which was then cold-pressed to obtain a preform.

[0043] (2) Then, a 10 kg aluminum ingot is placed in a graphite mold at the bottom of the vacuum impregnation furnace, and the preform is placed in the upper part of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until it melts to obtain molten metal. The preform is preheated and immersed in the molten metal. The heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide, aluminum nitride, and silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0044] (3) Finally, the green body is subjected to microwave sintering treatment under vacuum and alternating magnetic field conditions to obtain the alumina reinforced aluminum-based composite material.

[0045] Wherein, in step (1), the nanorod-shaped zirconium boride is prepared by the following method: first, 60g of zirconium oxide, 20g of boron carbide, 10g of amorphous carbon, 30g of sodium chloride, and 50g of potassium chloride are mixed evenly, irradiated with 800W microwaves for 8 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 3 times, and vacuum dried to obtain the obtained product.

[0046] The ultrasonic dispersion conditions are: 400W ultrasonic dispersion for 20 minutes; the ultrasonic oscillation uniformity conditions are: 600W ultrasonic oscillation treatment for 40 minutes.

[0047] The cold pressing conditions were: 50 MPa for 20 minutes.

[0048] In step (2), the aluminum ingot is heated to 780° C. and kept at this temperature for 1 hour to obtain molten metal.

[0049] The preform was preheated at 8°C / min to 580°C and kept at that temperature for 1 hour.

[0050] The flow rate of the mixed gas was 1 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas was 7:3.

[0051] In step (3), the alternating magnetic field conditions are: magnetic induction intensity is 3T, and frequency is 60Hz.

[0052] The microwave sintering frequency is 800MHz, and the specific process is as follows:

[0053] (A) sintering at 300W for 20 minutes;

[0054] (B) sintering at 700W for 3 minutes;

[0055] (C) Sintering at 400W for 5 minutes.

[0056] Example 2

[0057] A method for preparing an alumina-reinforced aluminum-based composite material for wind turbine blade components, comprising the following specific steps:

[0058] (1) First, 0.07 kg of nanorod-shaped zirconium boride, 1.2 kg of aluminum metal powder, 0.12 kg of nanodiamond, and 0.28 kg of active silicon powder were ultrasonically dispersed in 8 kg of 50% ethanol aqueous solution, and then 2 kg of auxiliary agent (polyvinyl alcohol 200, polyethyleneimine, etc.) was added. Ultrasonic vibration was uniformly applied, and the precipitate was centrifuged and dried to obtain a mixed powder, which was then cold-pressed to obtain a preform.

[0059] (2) Then, a 10 kg aluminum ingot is placed in a graphite mold at the bottom of the vacuum impregnation furnace, and the preform is placed in the upper part of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until it melts to obtain molten metal. The preform is preheated and immersed in the molten metal. The heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide, aluminum nitride, and silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0060] (3) Finally, the green body is subjected to microwave sintering treatment under vacuum and alternating magnetic field conditions to obtain the alumina reinforced aluminum-based composite material.

[0061] Wherein, in step (1), the nanorod-shaped zirconium boride is prepared by the following method: first, 70g of zirconium oxide, 24g of boron carbide, 12g of amorphous carbon, 40g of sodium chloride, and 60g of potassium chloride are mixed uniformly, irradiated with 1000W microwaves for 10 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 3 to 5 times, and vacuum dried to obtain the obtained product.

[0062] The ultrasonic dispersion conditions are: 500W ultrasonic dispersion for 30 minutes; the ultrasonic oscillation uniformity conditions are: 700W ultrasonic oscillation treatment for 50 minutes.

[0063] The cold pressing conditions were: 60 MPa for 30 minutes.

[0064] In step (2), the aluminum ingot is heated to 800° C. and kept at this temperature for 2 hours to obtain molten metal.

[0065] The preform was preheated at 10°C / min to 600°C and kept at this temperature for 2 hours.

[0066] The flow rate of the mixed gas is 2 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas is 7:3.

[0067] In step (3), the alternating magnetic field conditions are: magnetic induction intensity is 4T, and frequency is 80Hz.

[0068] The microwave sintering frequency is 1000MHz, and the specific process is as follows:

[0069] (A) 500W sintering for 30 minutes;

[0070] (B) sintering at 800W for 5 minutes;

[0071] (C) Sintered at 600W for 7 minutes.

[0072] Example 3

[0073] A method for preparing an alumina-reinforced aluminum-based composite material for wind turbine blade components, comprising the following specific steps:

[0074] (1) First, 0.05 kg of nanorod-shaped zirconium boride, 1.2 kg of aluminum metal powder, 0.12 kg of nanodiamond, and 0.28 kg of active silicon powder were ultrasonically dispersed in 6 kg of 50% ethanol aqueous solution, and then 1 kg of an auxiliary agent (polyvinyl alcohol 200, polyethyleneimine, etc.) was added. Ultrasonic vibration was uniformly applied, and the precipitate was centrifuged and dried to obtain a mixed powder, which was then cold-pressed to obtain a preform.

[0075] (2) Then, a 10 kg aluminum ingot is placed in a graphite mold at the bottom of the vacuum impregnation furnace, and the preform is placed in the upper part of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until it melts to obtain molten metal. The preform is preheated and immersed in the molten metal. The heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide, aluminum nitride, and silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0076] (3) Finally, the green body is subjected to microwave sintering treatment under vacuum and alternating magnetic field conditions to obtain the alumina reinforced aluminum-based composite material.

[0077] Wherein, in step (1), the nanorod-shaped zirconium boride is prepared by the following method: first, 70g of zirconium oxide, 20g of boron carbide, 12g of amorphous carbon, 30g of sodium chloride, and 60g of potassium chloride are mixed uniformly, irradiated with 800W microwaves for 10 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 3 to 5 times, and vacuum dried to obtain the obtained product.

[0078] The ultrasonic dispersion conditions are: 400W ultrasonic dispersion for 30 minutes; the ultrasonic oscillation uniformity conditions are: 600W ultrasonic oscillation treatment for 50 minutes.

[0079] The cold pressing conditions were: 50 MPa for 30 minutes.

[0080] In step (2), the aluminum ingot is heated to 780° C. and kept at this temperature for 2 hours to obtain molten metal.

[0081] The preform was preheated at 8°C / min to 600°C and kept at that temperature for 1 hour.

[0082] The flow rate of the mixed gas is 2 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas is 7:3.

[0083] In step (3), the alternating magnetic field conditions are: magnetic induction intensity is 3T, and frequency is 80Hz.

[0084] The microwave sintering frequency is 800MHz, and the specific process is as follows:

[0085] (A) sintering at 500W for 20 minutes;

[0086] (B) sintering at 800W for 3 minutes;

[0087] (C) Sintering at 600W for 5 minutes.

[0088] Example 4

[0089] A method for preparing an alumina-reinforced aluminum-based composite material for wind turbine blade components, comprising the following specific steps:

[0090] (1) First, 0.06 kg of nanorod-shaped zirconium boride, 1.1 kg of aluminum metal powder, 0.12 kg of nanodiamond, and 0.28 kg of active silicon powder were ultrasonically dispersed in 7 kg of 45% ethanol aqueous solution, and then 1.5 kg of auxiliary agent (polyvinyl alcohol 200, polyethyleneimine, etc.) was added. Ultrasonic vibration was uniformly applied, and the precipitate was centrifuged and dried to obtain a mixed powder, which was then cold-pressed to obtain a preform.

[0091] (2) Then, a 10 kg aluminum ingot is placed in a graphite mold at the bottom of the vacuum impregnation furnace, and the preform is placed in the upper part of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until it melts to obtain molten metal. The preform is preheated and immersed in the molten metal. The heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide, aluminum nitride, and silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0092] (3) Finally, the green body is subjected to microwave sintering treatment under vacuum and alternating magnetic field conditions to obtain the alumina reinforced aluminum-based composite material.

[0093] Wherein, in step (1), the nanorod-shaped zirconium boride is prepared by the following method: first, 66g of zirconium oxide, 22g of boron carbide, 11g of amorphous carbon, 36g of sodium chloride, and 56g of potassium chloride are mixed evenly, irradiated with 900W microwaves for 9 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 4 times, and vacuum dried to obtain the obtained product.

[0094] The ultrasonic dispersion conditions are: 500W ultrasonic dispersion for 25 minutes; the ultrasonic oscillation uniformity conditions are: 700W ultrasonic oscillation treatment for 45 minutes.

[0095] The cold pressing conditions were: 55 MPa for 25 minutes.

[0096] In step (2), the aluminum ingot is heated to 790° C. and kept at this temperature for 1.5 hours to obtain molten metal.

[0097] The preform was preheated at 9°C / min to 590°C and kept at that temperature for 1.5 hours.

[0098] The flow rate of the mixed gas was 1.5 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas was 7:3.

[0099] In step (3), the alternating magnetic field conditions are: magnetic induction intensity is 4T, and frequency is 70Hz.

[0100] The microwave sintering frequency is 900MHz, and the specific process is as follows:

[0101] (A) sintering at 4500W for 25 minutes;

[0102] (B) sintering at 750W for 4 minutes;

[0103] (C) Sintering at 500W for 6 minutes.

[0104] Comparative Example 1

[0105] A method for preparing an aluminum-based composite material, comprising the following specific steps:

[0106] (1) First, 1 kg of aluminum metal powder, 0.12 kg of nanodiamonds, and 0.28 kg of active silicon powder were ultrasonically dispersed in 6 kg of 40% ethanol aqueous solution, and then 1 kg of an auxiliary agent (polyvinyl alcohol 200, polyethyleneimine, etc.) was added. Ultrasonic vibration was uniformly applied, and the precipitate was centrifuged and dried to obtain a mixed powder, which was then cold-pressed to obtain a preform.

[0107] (2) Then, a 10 kg aluminum ingot is placed in a graphite mold at the bottom of the vacuum impregnation furnace, and the preform is placed in the upper part of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until it melts to obtain molten metal. The preform is preheated and immersed in the molten metal. The heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide, aluminum nitride, and silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0108] (3) Finally, the green body is subjected to microwave sintering treatment under vacuum and alternating magnetic field conditions to obtain the aluminum-based composite material.

[0109] Wherein, in step (1), the ultrasonic dispersion condition is: 400W ultrasonic dispersion for 20 minutes; the ultrasonic oscillation uniformity condition is: 600W ultrasonic oscillation treatment for 40 minutes.

[0110] The cold pressing conditions were: 50 MPa for 20 minutes.

[0111] In step (2), the aluminum ingot is heated to 780° C. and kept at this temperature for 1 hour to obtain molten metal.

[0112] The preform was preheated at 8°C / min to 580°C and kept at that temperature for 1 hour.

[0113] The flow rate of the mixed gas was 1 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas was 7:3.

[0114] In step (3), the alternating magnetic field conditions are: magnetic induction intensity is 3T, and frequency is 60Hz.

[0115] The microwave sintering frequency is 800MHz, and the specific process is as follows:

[0116] (A) sintering at 300W for 20 minutes;

[0117] (B) sintering at 700W for 3 minutes;

[0118] (C) Sintering at 400W for 5 minutes.

[0119] Comparative Example 2

[0120] A method for preparing an aluminum-based composite material, comprising the following specific steps:

[0121] (1) First, 0.05 kg of nanorod-shaped zirconium boride and 1 kg of aluminum metal powder were ultrasonically dispersed in 6 kg of 40% ethanol aqueous solution, and then 1 kg of auxiliary agent (polyvinyl alcohol 200, polyethyleneimine, etc.) was added. Ultrasonic vibration was uniformly applied, and the precipitate was centrifuged and dried to obtain a mixed powder, which was then cold-pressed to obtain a preform.

[0122] (2) Then, a 10 kg aluminum ingot is placed in a graphite mold at the bottom of the vacuum impregnation furnace, and the preform is placed in the upper part of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until it melts to obtain molten metal. The preform is preheated and immersed in the molten metal. The heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide and aluminum nitride in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0123] (3) Finally, the green body is subjected to microwave sintering treatment under vacuum and alternating magnetic field conditions to obtain the aluminum-based composite material.

[0124] Wherein, in step (1), the nanorod-shaped zirconium boride is prepared by the following method: first, 60g of zirconium oxide, 20g of boron carbide, 10g of amorphous carbon, 30g of sodium chloride, and 50g of potassium chloride are mixed evenly, irradiated with 800W microwaves for 8 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 3 times, and vacuum dried to obtain the obtained product.

[0125] The ultrasonic dispersion conditions are: 400W ultrasonic dispersion for 20 minutes; the ultrasonic oscillation uniformity conditions are: 600W ultrasonic oscillation treatment for 40 minutes.

[0126] The cold pressing conditions were: 50 MPa for 20 minutes.

[0127] In step (2), the aluminum ingot is heated to 780° C. and kept at this temperature for 1 hour to obtain molten metal.

[0128] The preform was preheated at 8°C / min to 580°C and kept at that temperature for 1 hour.

[0129] The flow rate of the mixed gas was 1 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas was 7:3.

[0130] In step (3), the alternating magnetic field conditions are: magnetic induction intensity is 3T, and frequency is 60Hz.

[0131] The microwave sintering frequency is 800MHz, and the specific process is as follows:

[0132] (A) sintering at 300W for 20 minutes;

[0133] (B) sintering at 700W for 3 minutes;

[0134] (C) Sintering at 400W for 5 minutes.

[0135] Comparative Example 3

[0136] A method for preparing an aluminum-based composite material, comprising the following specific steps:

[0137] (1) First, 0.05 kg of nanorod-shaped zirconium boride, 0.12 kg of nanodiamond, and 0.28 kg of active silicon powder were ultrasonically dispersed in 6 kg of 40% ethanol aqueous solution, and then 1 kg of an auxiliary agent (polyvinyl alcohol 200, polyethyleneimine, etc.) was added. Ultrasonic vibration was uniformly applied, and the precipitate was centrifuged and dried to obtain a mixed powder, which was then cold-pressed to obtain a preform.

[0138] (2) Then, a 10 kg aluminum ingot is placed in a graphite mold at the bottom of the vacuum impregnation furnace, and the preform is placed in the upper part of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until it melts to obtain molten metal. The preform is preheated and immersed in the molten metal. The heating is stopped to generate silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0139] (3) Finally, the green body is subjected to microwave sintering treatment under vacuum and alternating magnetic field conditions to obtain the aluminum-based composite material.

[0140] Wherein, in step (1), the nanorod-shaped zirconium boride is prepared by the following method: first, 60g of zirconium oxide, 20g of boron carbide, 10g of amorphous carbon, 30g of sodium chloride, and 50g of potassium chloride are mixed evenly, irradiated with 800W microwaves for 8 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 3 times, and vacuum dried to obtain the obtained product.

[0141] The ultrasonic dispersion conditions are: 400W ultrasonic dispersion for 20 minutes; the ultrasonic oscillation uniformity conditions are: 600W ultrasonic oscillation treatment for 40 minutes.

[0142] The cold pressing conditions were: 50 MPa for 20 minutes.

[0143] In step (2), the aluminum ingot is heated to 780° C. and kept at this temperature for 1 hour to obtain molten metal.

[0144] The preform was preheated at 8°C / min to 580°C and kept at that temperature for 1 hour.

[0145] In step (3), the alternating magnetic field conditions are: magnetic induction intensity is 3T, and frequency is 60Hz.

[0146] The microwave sintering frequency is 800MHz, and the specific process is as follows:

[0147] (A) sintering at 300W for 20 minutes;

[0148] (B) sintering at 700W for 3 minutes;

[0149] (C) Sintering at 400W for 5 minutes.

[0150] Comparative Example 4

[0151] A method for preparing an aluminum-based composite material, comprising the following specific steps:

[0152] (1) First, 0.05 kg of nanorod-shaped zirconium boride, 1 kg of aluminum metal powder, 0.12 kg of nanodiamond, and 0.28 kg of active silicon powder were ultrasonically dispersed in 6 kg of 40% ethanol aqueous solution, and then 1 kg of auxiliary agent (polyvinyl alcohol 200, polyethyleneimine, etc.) was added. Ultrasonic vibration was uniformly applied, and the precipitate was centrifuged and dried to obtain a mixed powder, which was then cold-pressed to obtain a preform.

[0153] (2) Then, a 10 kg aluminum ingot is placed in a graphite mold at the bottom of the vacuum impregnation furnace, and the preform is placed in the upper part of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until it melts to obtain molten metal. The preform is preheated and immersed in the molten metal. The heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide, aluminum nitride, and silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0154] (3) Finally, the green body is subjected to microwave sintering treatment under vacuum conditions to obtain the aluminum-based composite material.

[0155] Wherein, in step (1), the nanorod-shaped zirconium boride is prepared by the following method: first, 60g of zirconium oxide, 20g of boron carbide, 10g of amorphous carbon, 30g of sodium chloride, and 50g of potassium chloride are mixed evenly, irradiated with 800W microwaves for 8 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 3 times, and vacuum dried to obtain the obtained product.

[0156] The ultrasonic dispersion conditions are: 400W ultrasonic dispersion for 20 minutes; the ultrasonic oscillation uniformity conditions are: 600W ultrasonic oscillation treatment for 40 minutes.

[0157] The cold pressing conditions were: 50 MPa for 20 minutes.

[0158] In step (2), the aluminum ingot is heated to 780° C. and kept at this temperature for 1 hour to obtain molten metal.

[0159] The preform was preheated at 8°C / min to 580°C and kept at that temperature for 1 hour.

[0160] The flow rate of the mixed gas was 1 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas was 7:3.

[0161] In step (3), the microwave sintering frequency is 800 MHz, and the specific process is as follows:

[0162] (A) sintering at 300W for 20 minutes;

[0163] (B) sintering at 700W for 3 minutes;

[0164] (C) Sintering at 400W for 5 minutes.

[0165] Comparative Example 5

[0166] A method for preparing an aluminum-based composite material, comprising the following specific steps:

[0167] (1) First, 0.05 kg of nanorod-shaped zirconium boride, 1 kg of aluminum metal powder, 0.12 kg of nanodiamond, and 0.28 kg of active silicon powder were ultrasonically dispersed in 6 kg of 40% ethanol aqueous solution, and then 1 kg of auxiliary agent (polyvinyl alcohol 200, polyethyleneimine, etc.) was added. Ultrasonic vibration was uniformly applied, and the precipitate was centrifuged and dried to obtain a mixed powder, which was then cold-pressed to obtain a preform.

[0168] (2) Then, a 10 kg aluminum ingot is placed in a graphite mold at the bottom of the vacuum impregnation furnace, and the preform is placed in the upper part of the vacuum impregnation furnace. The vacuum impregnation furnace is sealed, and the aluminum ingot is heated until it melts to obtain molten metal. The preform is preheated and immersed in the molten metal. The heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide, aluminum nitride, and silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body;

[0169] (3) Finally, the blank is treated under vacuum and alternating magnetic field conditions to obtain the aluminum-based composite material.

[0170] Wherein, in step (1), the nanorod-shaped zirconium boride is prepared by the following method: first, 60g of zirconium oxide, 20g of boron carbide, 10g of amorphous carbon, 30g of sodium chloride, and 50g of potassium chloride are mixed evenly, irradiated with 800W microwaves for 8 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 3 times, and vacuum dried to obtain the obtained product.

[0171] The ultrasonic dispersion conditions are: 400W ultrasonic dispersion for 20 minutes; the ultrasonic oscillation uniformity conditions are: 600W ultrasonic oscillation treatment for 40 minutes.

[0172] The cold pressing conditions were: 50 MPa for 20 minutes.

[0173] In step (2), the aluminum ingot is heated to 780° C. and kept at this temperature for 1 hour to obtain molten metal.

[0174] The preform was preheated at 8°C / min to 580°C and kept at that temperature for 1 hour.

[0175] The flow rate of the mixed gas was 1 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas was 7:3.

[0176] In step (3), the alternating magnetic field conditions are: magnetic induction intensity of 3 T, frequency of 60 Hz, and treatment time of 28 minutes.

[0177] Test example

[0178] The properties of the aluminum-based composite materials obtained in Examples 1 to 4 and Comparative Examples 1 to 5 were investigated respectively.

[0179] 1. Mechanical properties: Refer to GB / T 228.1-2021 "Tensile tests on metallic materials - Part 1: Room temperature test methods" to test tensile strength.

[0180] 2. Anti-aging performance: UV intensity 3000μW / cm 2 Condition exposure test, continuous irradiation for 60 days and then test the tensile strength again.

[0181] 3. Corrosion resistance: A 10 mm × 10 mm × 3 mm aluminum matrix composite material was immersed in a 10% sodium hydroxide solution and a 5% hydrochloric acid solution, respectively. The composite material was allowed to stand at room temperature for 300 hours and the corrosion weight loss was measured. The results are shown in Table 1.

[0182] Table 1. Performance investigation results of aluminum matrix composite materials

[0183]

[0184] As can be seen from Table 1, the aluminum-based composite materials obtained in Examples 1 to 4 have excellent mechanical properties, anti-aging properties and corrosion resistance, and are suitable for the manufacture of wind turbine blade components.

[0185] In Comparative Example 1, nanorod-shaped zirconium boride was omitted, nanodiamonds and active silicon powder were omitted, the introduction of aluminum metal powder and mixed gas was omitted in Comparative Example 3, the alternating magnetic field conditions were omitted in Comparative Example 4, and microwave sintering treatment was omitted in Comparative Example 5. The performance of the aluminum-based composite material deteriorated significantly, indicating that the synergistic effect of nanorod-shaped zirconium boride, aluminum oxide, aluminum nitride, silicon carbide, etc. promoted the improvement of the performance of the aluminum-based composite material, and the alternating magnetic field conditions and microwave sintering treatment further optimized the product performance.

[0186] While the present invention is illustrated by the aforementioned embodiments, the present invention is not limited to these embodiments, nor does it necessarily rely on these embodiments for implementation. Those skilled in the art will appreciate that any improvements to the present invention, equivalent replacements for individual raw materials in the present invention, additions of auxiliary ingredients, and selection of specific methods, etc., fall within the scope of protection and disclosure of the present invention.

Claims

1. A method for preparing an alumina reinforced aluminum-based composite material for wind turbine blade components, characterized in that: The specific steps are as follows: (1) First, nanorod-shaped zirconium boride, aluminum metal powder, nanodiamond, and active silicon powder are ultrasonically dispersed in an ethanol aqueous solution, and then an auxiliary agent is added, ultrasonically vibrated evenly, centrifuged to obtain a precipitate, dried to obtain a mixed powder, and cold pressed to obtain a preform; (2) then placing the aluminum ingot in a graphite mold at the bottom of the vacuum impregnation furnace, placing the preform in the upper part of the vacuum impregnation furnace, sealing the vacuum impregnation furnace, heating the aluminum ingot until it melts to obtain molten metal, and immersing the preform in the molten metal after preheating. Heating is stopped, and a mixed gas of oxygen and nitrogen is introduced into the vacuum impregnation furnace to generate aluminum oxide, aluminum nitride, and silicon carbide in situ. After the temperature in the vacuum impregnation furnace is naturally cooled to room temperature, the introduction of the mixed gas is stopped to obtain a green body; (3) Finally, the green body is subjected to microwave sintering treatment under vacuum and alternating magnetic field conditions to obtain the alumina reinforced aluminum-based composite material.

2. The preparation method according to claim 1, characterized in that The mass ratio of nanorod-shaped zirconium boride, aluminum metal powder, nanodiamond, active silicon powder, ethanol aqueous solution, additive and aluminum ingot is 0.05-0.07:1-1.2:0.12:0.28:6-8:1-2:10, the volume concentration of ethanol aqueous solution is 40-50%, and the additive is obtained by mixing polyvinyl alcohol 200, polyethyleneimine and the like.

3. The preparation method according to claim 1, characterized in that In step (1), the nanorod-shaped zirconium boride is prepared by the following method, in parts by weight: 30 to 35 parts of zirconium oxide, 10 to 12 parts of boron carbide, 5 to 6 parts of amorphous carbon, 15 to 20 parts of sodium chloride, and 25 to 30 parts of potassium chloride are uniformly mixed, irradiated with 800 to 1000 W microwaves for 8 to 10 minutes under an argon atmosphere, naturally cooled to room temperature, washed with deionized water 3 to 5 times, and vacuum dried to obtain the obtained product.

4. The preparation method according to claim 1, characterized in that In step (1), the ultrasonic dispersion conditions are: 400-500W ultrasonic dispersion for 20-30 minutes; the ultrasonic oscillation uniformity conditions are: 600-700W ultrasonic oscillation treatment for 40-50 minutes.

5. The preparation method according to claim 1, characterized in that In step (1), the cold pressing condition is: 50-60 MPa cold pressing for 20-30 minutes.

6. The preparation method according to claim 1, characterized in that In step (2), the aluminum ingot is heated to 780-800° C. and kept warm for 1-2 hours to obtain molten metal.

7. The preparation method according to claim 1, characterized in that In step (2), the preform is preheated by heating to 580-600°C at 8-10°C / min and keeping the temperature for 1-2 hours; The flow rate of the mixed gas is 1-2 L / min, and the volume ratio of oxygen to nitrogen in the mixed gas is 7:

3.

8. The preparation method according to claim 1, characterized in that In step (3), the alternating magnetic field conditions are: magnetic induction intensity is 3 to 4 T, and frequency is 60 to 80 Hz; The microwave sintering frequency is 800-1000MHz, and the specific process is as follows: (A) sintering at 300-500W for 20-30 minutes; (B) sintering at 700-800W for 3-5 minutes; (C) Sinter at 400-600W for 5-7 minutes.

9. An alumina reinforced aluminum matrix composite material for wind turbine blade components, characterized in that: It is prepared by the method according to any one of claims 1 to 8.

10. Use of the alumina reinforced aluminum-based composite material according to claim 9 in the manufacture of wind turbine blade components.

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